Radially non-symmetric beam forming elements for correction of energy profile distortion due to lateral beam drift

ABSTRACT

A radially non-symmetric beamforming element for transforming the input energy profile of an input laser beam subject to lateral shift that is variable in radial direction and magnitude into a desired output energy profile of an output laser beam. The beam forming element includes an optical element having a profile transformation function that includes a first profile transformation function for transforming the input energy profile into the desired output energy profile and a profile correction transformation function superimposed on the first profile transformation function for modifying the first profile transformation function to correct distortions in the output energy profile introduced be a lateral shift of the input laser beam. The profile correction transformation function includes a deficiency profile transformation function or a hotspot profile transformation function and an optical axis of the optical element is aligned parallel to the beam axis of the input laser beam and is offset from an unshifted beam axis of the input laser beam by a distance proportionate to a maximum expected lateral shift of the beam axis of the input laser beam.

CROSS REFERENCE TO RELATED APPLICATIONS

The present invention is a continuation-in-part of and claims benefit ofpresently pending U.S. patent application Ser. No. 10/958,712 filed Oct.5, 2004 by Todd E. LIZOTTE for COMPENSATOR OPTICS TO IMPROVE THESTABILITY OF BEAM DELIVERY SYSTEMS THAT UTILIZE BEAM SHAPING TECHNOLOGY,which is a continuation-in-part of and claims benefit of U.S. patentapplication Ser. No. 10/411,570 filed Apr. 10, 2003 by Todd E. Lizottefor CORRECTION OF ANGULAR DEVIATION AND RADIAL DRIFT OF LASER BEAMS andsince allowed.

FIELD OF THE INVENTION

The present invention relates to the control and correction of laserpointing and thermal drift instability in laser beam delivery systemsand, in particular, to radially non-symmetric beamforming elements forcorrection of laser beam energy profile distortions due to lateral beamshifts.

BACKGROUND OF THE INVENTION

Focused and directed laser beams are commonly used for a variety ofprocesses, such as drilling of blind, through and micro-vias, laserimaging, dicing of substrates and modification or customization ofintegrated circuits, drilling, cutting, and selective material removaland other complex machining and micro-machining operations involvingmaterials such as metals, polymers, integrated circuits, substrates,ceramics and other materials. Such processes have become very complex,often involving the concurrent or sequential of use of single ormultiple lasers or multiple types of lasers, such as visible, infra-red(IR) and ultraviolet (UV) lasers, in concurrent or sequentialoperations. In generally all such laser processes, however, the generalobject of a laser system is to controllably and reliably direct, focusand concentrate the energy of one or more laser beans to converge eachbeam at a desired spot or to image an apertured area of a laser beamonto the surface of an object.

A number recurring problems of conventional laser systems of the priorart, however, directly affect the reliable and controllable “pointing”of a laser beam to a desired location. The first, which is illustratedin FIGS. 1A and 1B, is often referred to as “beam wobble” or “pointinginstability” and is the radial deviation of the Beam Axis 10 a LaserBeam 12 from an Optimum Centerline 14 by a Deviation Angle θ and isoften related to variations in the pulse energy of the laser beam, whichis often referred to as “pumping jitter”. Pointing instability isessentially inherent in both the properties of a Laser 16 itself and inthe normal operations of a Laser 16, such as “pumping jitter”.

A second problem of the prior art is illustrated in FIGS. 2A and 2B andis often referred to as “thermal drift”, which again causes the BeamAxis 10 of a Laser Beam 12 to drift from an Optimum Centerline 14.Thermal drift is generally regarded as due to changes in the parametersof the Laser 16 due to changes in the laser duty cycle, heating duringoperation, changes in power levels of the Laser 16. It should be notedthat, unlike “pointing instability” which results in an angulardeviation of the Beam Axis 10 from the Optimum Centerline 14, “thermaldrift” results in a linear radial drift of the Beam Axis 10 with respectto the Optimum Centerline 14. That is, the Beam Axis 10 of a Laser Beam12 remains parallel to the axis of Optimum Centerline 14, but driftsradially away from Optimum Centerline 14.

Yet a third problem of the prior art is that of beam mode changes overtime, which results in “hot spots”, or distortions of the beam profile.If the profile of the beam is non-uniform or does not have an optimumGaussian profile, the shape of the profile cannot be subsequently shapedinto the preferred “flat top” profile, which will adversely effect thequality of the processes performed by the laser system, such asmicro-machining or the drilling of microvias. This problem is furthercompounded, of course, by pointing instabilities and thermal drift.

Effectively all lasers used for micro-machining, such as microviadrilling, exhibit pointing instability, thermal drift and profiledistortion, and there have been many attempts to correct or at leastcontrol these problems. For example, laser systems of the prior art haveattempted to correct the effects of “pointing instability” and “thermaldrift” by the use of actively controlled servo-mirrors, which arecontrolled to redirect a laser beam so as to correct for the “pointinginstability” and “thermal drift”. Such methods, however, requiredetecting and comparing the actual path of a beam due to pointinginstability or thermal instability with the desired optimum path for thebeam and controlling the servo-mirrors so as to direct the beam into thedesired path. Not only are such methods complex and expensive, but theyhave an inherent time delay in detecting and correcting the effects ofpointing instability or thermal drift, and introduce errors of their owndue to mechanical and control system tolerances and have thereby notprovided completely satisfactory solutions to these problems.

Other approaches of the prior art to these problems have used opticalelements in the laser beam path to correct for pointing instabilitiesand thermal drift and to shape the beam into the optimum Gaussian andflat-top profiles for micro-machining, such as the drilling ofmicrovias. A recurring problem, however, is that when the an opticalbeam shaping system is illuminated poorly, that is, either at anincident angle or with a laterally displaced beam, such as may resultfrom pointing instabilities, thermal drift or hot spots, the opticalbeam shaping elements are not able to shape the laser beam into thedesired profile.

The basic problems arising with the use of optical elements to corrector compensate for pointing instability and thermal drift are illustratedin FIGS. 3A and 3B with respect to the use of holographic opticalelements (HOEs) and standard symmetric holographic optical element(SSHOEs) employed as beam shaping elements. FIG. 3A, for example,illustrates the results of radial displacement due to thermal drifteffects in the case of a Holographic Optical Element (HOE) and, inparticular, with respect to a Standard Symmetric Holographic OpticalElement (SSHOE) 18, or an equivalent lens. Because the SSHOE 18 issymmetric, a Laser Beam 12A that enters the SSHOE 18 along a Beam Axis10A that is parallel to the HOE Axis 20 will exit the SSHOE 18 as LaserBeam 12B on Beam Axis 10B wherein Beam Axis 10B is coaxial with and alinear continuation of Beam Axis 10B.

More specifically, a Laser Beam 12A entering the SSHOE 18 along a BeamAxis 10A that is parallel to but radially displaced by a distance D fromthe HOE Axis 20 will exit the SSHOE 18 along the same Beam Axis 10A,indicated as Beam Axis 10B, and will remain radially displaced withrespect to the HOE Axis 20 by a distance D. As such, a SSHOE 18 orequivalent symmetric lens will not radially redirect the Beam Axis 10 ofan entering Laser Beam 12 with respect to the HOE Axis 20 of the SSHOE18, and thereby cannot correct for or control thermal drift effects.

Referring to FIG. 3B, a Laser Beam 12A effected by “pointinginstability” will enter an Entry Face 22 of the SSHOE 18 along Beam Axis10A having an angular deviation θ with respect to the HOE Axis 20, thatis, will not be parallel with the HOE Axis 20. Because of the symmetryof a SSHOE 18 or equivalent symmetric lens, however, the Laser Beam 12Bwill exit the Exit Face 24 of the SSHOE 18 along a Beam Axis 10B that isthe continuation of the Beam Axis 10A along which the Laser Beam 12Aentered the SSHOE 18. As in the case of thermal drift, therefore,conventional SSHOEs 18 and similar symmetric lenses cannot correct foror control pointing instability and the resulting angular deviation ofthe Beam Axis 10.

Instability and shifting in the input beams to beamshifting elements,however, can frequently lead to yet other problems in typical beamdelivery systems, such as a micro-machining system for the drilling ofmicrovias, by distortion of the laser beams generated by the beamshapingoptics of the system.

For example, in a typical laser beam delivery system such as illustratedin FIGS. 4A through 4D, the Laser 12 is typically comprised of diodepumped solid state (DPSS) laser or a Diode Pumped Fiber (DPFL) laser,which tend to generate TEM00 single mode laser beams with optimumGaussian energy profiles. In a typical system such as illustrated inFIGS. 4A through 4D, Beamshaping Optics 26 are used to reshape an OutputBeam 12I having an optimum Gaussian Profile 12GP into an Output Beam 12Ohaving a Flat-Top Profile 12FP, that is, a uniform energy profileparticularly advantageous for micromachining operations, and aretypically comprised of, for example, diffractive or holographic beamdiffusers or shaping optics.

As is well known, the Input Beam 12I generated by a Laser 12 will tendto drift laterally by amounts ranging from a few microns to severalhundreds of microns with changes in the Laser 12 parameters, such as thepump diode current changes, harmonic crystal shifts, changes in thepulsing frequency or repetition rate, and so on. The typical results ofsuch lateral drifts of the Beam Axis 10 of a Input Beam 12I from anOptimum Centerline 14 that is coaxial with the Optical Centerline 26C ofBeamshaping Optics 26 are represented diagrammatically in FIGS. 4A, 4B,4C and 4D. FIGS. 4A and 4B illustrate the situation wherein the BeamAxis 10 of Input Beam 12I is coaxial with Optical Centerline 26C ofBeamshaping Optics 26, with FIG. 4B being a superimposed comparison ofthe energy profiles of Input Beam 12I and the resulting Output Beam 12O.FIGS. 4C and 4D, in turn, illustrate the situation wherein the Beam Axis10 of Input Beam 12I is laterally offset with respect to the OpticalCenterline 26C of Beamshaping Optics 26, with FIG. 4D again being asuperimposed comparison of the energy profiles of the input and outputbeams.

As illustrated in FIGS. 4A through 4D, each lateral shift of the InputBeam 12I with respect to the axis of Beamshaping Optics 26, however,that is, each shift from the situation of FIGS. 4A and 4B to thesituation of FIGS. 4C and 4D, will result in a non-uniform energyprofile in Output Beam 12O. In the typical situation as illustrated inFIGS. 4C and 4D, for example, a Lateral Offset 64O of Input Beam 12Iwill result in the generation of either or both of a “Hotspot” 64S inthe energy profile of Output Beam 12O and a deficiency or “Deficiency”64D in the energy profile of Output Beam 12O. As illustrated, a Hotspot64S is a region of an energy profile in which the energy level is higherthan desired while a Deficiency 64D is a region of an energy profile inwhich the energy level is lower than desired. In this regard, it shouldbe noted that Hotspots 64S are typically formed on the side of theenergy profile in the direction of the Lateral Offset 64O of the InputBeam 12I, with Deficiencies 64D typically appearing in the energyprofile in the direction opposite to the Lateral Offset 64O.

Such distortions in the energy profiles of the Output Beam 12O obviouslydegrade the performance of a laser beam delivery system such as a lasermicromaching system. As a result, each such shift of the beam axisrequires either a realignment of the beam delivery system in order torestore the desired Flat-Top Profile 12F of Output Beam 12O. Therequired realignment of the system may be accomplished by either or bothof a realignment of Beamshaping Optics 26 to the new location of BeamAxis 10 of Input Beam 12I or a realignment of Beam Axis 10 of Input Beam12I to the Optical Centerline 26C of Beamshaping Optics 26, either ofwhich represents a significant down time for the system. It will beappreciated that the need to realign the laser beam system optics or thelaser beam for each lateral shift of the laser beam, regardless of thecause of the shift, will be a significant problem as an industrial lasersystem on the production floor will typically, and for example, requirerealignment several times a day or even several times a work shift.

In this regard, it must also be noted that while non-symmetric opticalelements, including compensator and remapping elements, may be employedto address some of the problems arising from unwanted lateral shifts ina laser beam, such non-symmetric elements are typically comprised ofholographic or diffractive optical elements. Such optical elementstypically have fixed characteristics that, because they are fixed whilethe possible lateral shifts of a laser beam are not fixed, may not beable to adequately address the full range of possible lateral shifts ofa laser beam in a given system.

The present invention provides a solution to these and related problemsof the prior art.

SUMMARY OF THE INVENTION

The present invention is directed to a radially non-symmetricbeamforming element for transforming the input energy profile of aninput laser beam into a desired output energy profile of an output laserbeam in systems wherein the beam axis of the input laser beam is subjectto lateral shift that is variable in radial direction and magnitude.

The beam forming element of the present invention includes an opticalelement having a profile transformation function that includes a firstprofile transformation function for transforming the input energyprofile into the desired output energy profile and a profile correctiontransformation function superimposed on the first profile transformationfunction for modifying the first profile transformation function tocorrect distortions in the output energy profile introduced be a lateralshift of the input laser beam.

In a presently preferred embodiment, the profile correctiontransformation function of the radially non-symmetric beamformingelement includes at least one of a deficiency profile transformationfunction and a hotspot profile transformation function. The deficiencyprofile transformation function is superimposed on the first profiletransformation function for superimposing a compensating deficiencyenergy profile on the desired output energy profile in a locationcorresponding to a hotspot resulting from a lateral shift of the inputlaser beam. The hotspot profile transformation function is likewisesuperimposed on the first profile transformation function forsuperimposing a compensating hotspot energy profile on the desiredoutput energy profile in a location corresponding to a deficiencyresulting from a lateral shift of the input laser beam.

Further according to the present invention, an optical axis of thebeamforming element is aligned parallel to the beam axis of the inputlaser beam and is offset from an unshifted beam axis of the input laserbeam by a distance proportionate to a maximum expected lateral shift ofthe beam axis of the input laser beam, so that the input laser beampasses through the beamforming element parallel to and offset from theoptical axis of the optical element.

In yet further embodiments, the beamforming element is supported in arotating mount allowing rotation of the profile transformation functionabout the optical axis of the optical element to allow adjustment of theprofile transformation function to a current lateral shift of the inputlaser beam.

BRIEF DESCRIPTION OF THE DRAWING(S)

The invention will now be described, by way of example, with referenceto the accompanying drawings in which:

FIGS. 1A and 1B are illustrative diagrams of angular deviation of alaser beam due to pointing instability;

FIGS. 2A and 2B are illustrative diagrams of radial drift of a laserbeam due to thermal drift;

FIGS. 3A and 3B are illustrative diagrams of radial displacement andangular deviation of laser beams;

FIGS. 4A and 4C are illustrative diagrams of beamshaping optics for,respectively, an input laser beam aligned with the axis of thebeamshaping optics and laterally offset with respect to the axis of thebeamshaping optics;

FIGS. 4B and 4D are illustrative superimposed comparisons of the inputand Output Beam energy profiles for the situations illustrated in FIGS.4A and 4C;

FIG. 5 is an illustrative diagram of a method of the present inventionfor correcting angular deviation or radial displacement;

FIGS. 6A, 6B, 6C, 6D, 6E and 6F are illustrative diagrams of opticalelements and combinations of optical elements for correcting angulardeviation and radial drift of laser beams;

FIGS. 7A, 7B and 7C are illustrative diagrams of systems in which thepresent invention is implemented; and

FIGS. 8A, 8B, 8D and 8E are illustrative diagrams of exemplarycompensators and remappers;

FIGS. 9A and 9B illustrate the operation of a non-symmetric beamformingoptical element;

FIG. 9C illustrates a non-symmetric beamforming optical element mountedin an offset mount;

FIG. 9D illustrates a non-symmetric beamforming optical element mountedin an offset mount by rotating bearings;

FIGS. 10A, 10B, 10C and 10D are phase surface and correspondingcross-section illustrations of two exemplary non-symmetric beamformingoptical elements according to the present invention; and,

FIGS. 11A through 11E illustrate cross sectional energy profiles oflaser beams according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

A. Introduction

The following will describe methods and apparatus for addressing theabove discussed problems of the prior art. In particular, the followingwill first describe and discuss methods and apparatus for the correctionof either or both of radial displacement due to thermal drift andangular deviation due to pointing instability by means of non-symmetricelements.

The following will then describe and discuss certain preferredembodiments of non-symmetric elements for the correction of radial(lateral) displacement and pointing instability in the form ofcompensator and remapping non-symmetric elements. As will be described,compensator and remapping elements accept an input beam over a range ofinput angles and lateral (radial) displacements and “remap” the energyprofile of the input beam to provide an output beam having an outputprofile that is optimum for a following element, such as beamshapingelements.

The following will then describe and discuss methods and apparatus forthe realignment of a laser beam that has drifted laterally (radially),the elimination of “hotspots” from the energy profile of the output beamof beamshaping elements, and the restoration of a desired energy profileto the output beam of beamshaping elements.

B. Correction of Radial Displacement and Pointing Instability ByNon-Symmetric Elements

As illustrated generally in FIGS. 6 and 6A through 6F, either or both ofradial displacement due to thermal drift and angular deviation due topointing instability may be corrected by means of a Non-SymmetricElement (NSE) 28 as illustrated in FIG. 6. As illustrated therein, anNSE 28 may be, for example, a Non-Symmetric Hologram Optical Element(NSHOE) or an equivalent optical element, such as a non-symmetric lensor a non-symmetric refraction element or a non-symmetric diffractionelement. As indicated, an NSE 28 differs from a SSHOE 18 or equivalentsymmetric element in that the path of the Beam Axis 10 of a Laser Beam12 traversing the NSE 28 is refracted, or turned, through a CorrectionAngle φ during the passage of the Laser Beam 12 through the NSE 28. Aswill be discussed further in the following, in one embodiment of a NSE28 the angle φ increases with increasing radial displacement Δ of theincident Beam Axis 10 from the Centerline Axis 28C of the NSE 28. In asecond embodiment of a NSE 28, the Correction Angle φ increases with andecreasing angle of incidence α of the Beam Axis 10 of the incidentLaser Beam 12 with respect to the plane surface of the NSE 28.

Examples of embodiments of Drift/Deviation Correction Elements 32 forcorrecting either or both of radial displacement due to thermal driftand angular deviation due to pointing instability are illustrated inFIGS. 6A, 6B and 6C.

FIG. 6A illustrates an embodiment of a Drift/Deviation CorrectionElement 32 for the correction of angular deviation of a Laser Beam 12due to pointing instability. As shown, in this instance theDrift/Deviation Correction Element 32 is comprised of a single NSE 28,28A, 28B, 28C, 28D or 28S such as a Non-Symmetric Hologram OpticalElement (NSHOE) or equivalent non-symmetric lens.

First considering the geometric aspects of angular deviation due topointing instability as illustrated in FIG. 6A, a Laser Beam 12 havingangular deviation resulting from pointing instability may be consideredas emitting from a point, that is, from Laser 16, such that the BeamAxis 10 of each Laser Beam 12 radiates outwards from that point at anangular deviation θ that is dependent upon the degree of wobble anduntil the Laser Beam 12 strikes the plane of the NSE 28. A considerationof the geometry of the elements shown in FIG. 6A will show that theangle of incidence α between the Beam Axis 10 and the plane of the NSE28A will decrease, in a reciprocal relationship, as the angulardeviation θ increases. It will also be apparent that the radialdisplacement Δ between the Centerline Axis 28C of the NSE 28A and thepoint at which the Beam Axis 10 is incident upon the NSE 28A increasesas the angular deviation θ increases. Stated another way, an angulardeviation θ will result in both an inversely proportionate angle ofincidence α with the NSE 28A and a proportionate radial displacement Δfrom the Centerline Axis 28C of the NSE 28A.

It will be apparent that the correction of angular deviation due topointing instability, requires that the Beam Axes 10 of the Laser Beams12 be redirected, that is, turned or refracted, through an CorrectionAngle φ to orient the Beam Axes 10 in the desired manner. In thisregard, and for example, the Correction Angle φ may be designed so thatthe Beam Axes 10 are parallel to HOE Axis 20 upon exiting the NSE 28A.In other instances, the Correction Angle φ may be designed to direct theLaser Beams 12 onto a selected point or area at a predetermined distancefrom the NSE 28A, such as at the entry face of a second NSE (not shown).

In either instance, and as may be seen from the above discussion ofangular deviation geometry, the magnitude of the Correction Angle φ musttherefore increase with either increasing radial displacement Δ or withdecreasing angle of incidence α. In a first embodiment of an AngularCorrection NSE 28A, therefore, the Angular Correction NSE 28A, which maybe, for example, a NSHOE or equivalent non-symmetric lens, is designedsuch that the Correction Angle φ increases proportionally to the radialdistance from the central axis of the Angular Correction NSE 28A. Asdescribed, therefore, the greater the angular deviation θ of a Beam Axis10 the greater the radial displacement Δ of the Beam Axis 10 from thecentral axis of the Angular Correction NSE 28A and the greater theCorrection Angle φ.

In a second embodiment of an Angular Correction NSE 28A, the AngularCorrection NSE 28A may be designed such that the Correction Angle φincreases with a decreasing angle of incidence α, that is, with anincreasing angular deviation θ of the Beam Axis 10. As may be seen,however, the two embodiments of an Angular Correction NSE 28A areequivalent because the relationship between angular deviation θ, angleof incidence a and radial displacement Δ.

As illustrated in FIG. 6A, therefore, the Angular Correction NSE 28A ofthe Drift/Deviation Correction Element 32 will correct an angulardeviation θ by turning, or refracting, the Laser Beam 12 through aCorrection Angle φ that is proportionate to the angular deviation θ. Theresult will therefore be that any Laser Beam 12 having a Beam Axis 10that is not parallel to the HOE Axis 20 will be turned through aCorrection Angle φ so that the Beam Axis 10 will be parallel to the HOEAxis 20 or so that the Beam Axis 10 is directed to a selected focalpoint or area.

The result of the operation of an Angular Correction NSE 28A isillustrated in FIG. 6B, which is an end view of a Laser 16 showing apossible distribution of Corrected Beams 12C about the OptimumCenterline 14 in comparison with a possible distribution of theUncorrected Beams 12U.

FIG. 6C, in turn, illustrates an embodiment of a Drift/DeviationCorrection Element 32 for the correction of radial displacement of aLaser Beam 12 due to thermal drift. As discussed previously, thermaldrift or similar causes of radial displacement result in a radialdisplacement of a Beam Axis 10 from a desired Optimum Centerline 14,rather than an angular deviation from the Optimum Centerline 14. Forthis reason, the radial displacement, that is, thermal drift, results ina Beam Axis 10 having an angle of incidence α of approximately 90° withrespect to a NSE 28 and correction of radial displacement Δ will be afunction of radial displacement Δ rather than of angle of incidence α.

As shown, in this instance the Drift/Deviation Correction Element 32 maybe comprised of a Displacement Correction NSE 28B followed by aCollimating NSE 28C, each of which may be, for example, Non-SymmetricHologram Optical Elements or equivalent non-symmetric lenses.

In this embodiment, and as discussed above, the Correction Angle φ ofDisplacement Correction NSE 28B increases radially and proportionatelyto the radial displacement Δ between Centerline Axis 28C of DisplacementCorrection NSE 28B and the point at which the Beam Axis 10 of a LaserBeam 12 is incident upon the plane of the Displacement Correction NSE28B. The effect of Drift Correction NSE 28B is therefore to refract orturn a Laser Beam 12 through a Correction Angle φ that is proportionateto the radial displacement Δ of the Beam Axis 10, that is, by an angleproportionate to the thermal drift of the Laser Beam 12. Because thedisplacement of Beam Axes 10 of Laser Beams 12 resulting from thermaldrift is radial, and the Beam Axis 10 of a Laser Beam 12 is therebyapproximately parallel to the Optimum Centerline 14, the Beam Axes 10are usually perpendicular to the entering face of the DisplacementCorrection NSE 28B. As such, the Correction Angle φ imposed by theDisplacement Correction NSE 28B will compress, that is, direct or focus,the Beam Axes 10 onto a point or small area at a fixed distance from theDisplacement Correction NSE 28B. As illustrated in FIG. 6C, the focuspoint of Displacement Correction NSE 28B is near or at the entry face ofthe second element of Drift/Deviation Correction Element 32, which isshown as Collimating NSE 28C.

Collimating NSE 28C is, in some respects, analogous to an inversetransform of an Angular Correction NSE 28A. That is, and as indicated,Laser Beams 12 enter Collimating NSE 28C from Correction NSE 28B suchthat their Beam Axes 10 generally are at an angle a with respect to theHOE Axis 20 of Collimating NSE 28C, that is, at an angle analogous to anangular deviation θ. As illustrated, Collimating NSE 28C redirects orturns each incoming Laser Beam 12 through a Correction Angle φ that isinversely proportionate to the angle of incidence α, so that the BeamAxes of the Laser Beams exiting Collimating NSE 28C are parallel.

A Drift/Deviation Correction Element 32 comprised of a DisplacementCorrection NSE 28B followed by a Collimating NSE 28C may thereby correctradial displacement due to thermal drift by first redirecting the LaserBeams 12 to reduce the radial displacement of each Laser Beam 12, byfocusing or directing the Laser Beams 12 into a defined area at adefined distance, and then by correcting the relative angles of the BeamAxes 10 to be parallel to the desired Optimum Centerline 14.

The operation of such a Drift/Deviation Correction Element 32 isillustrated in FIG. 6D, which illustrates a possible distribution ofCorrected Beams 12C about the Optimum Centerline 14 in comparison withUncorrected Beams 12U.

Next considering the case illustrated in FIG. 6E, it will be apparentthat angular deviation due to pointing instability and radialdisplacement due to thermal drift will rarely occur in isolation andthat it will be common for both effects to be present in a givensituation. As such, the Beam Axes 12 many if not all Laser Beams 12 willshow both angular deviation and radial displacement and the radialdistance from the Centerline Axis 28C of the NSE 28D at which a givenLaser Beam 12 will impinge upon a NSE 28D may be due to radialdisplacement, or due to angular deviation or due to both in varyingdegrees.

As such, a two element Drift/Deviation Correction Element 32 may beconstructed using, for example, a Deviation Correction NSE 28A followedby a Displacement Correction NSE 28B. Each would function as describedabove so that the combination would first correct the angular deviationof the Laser Beams 12, redirecting each Laser Beam 12 through aCorrection Angle φ dependent upon the angular deviation to Output Beams12 having parallel Beam Axes 10. The first stage would therefore, and ineffect, change angular deviation into radial displacement, and radialdisplacement into angular displacement, so that the Output Beams 12would demonstrate only radial displacement. The second stage would thencorrect radial displacement, as discussed with regard to FIG. 6C, toprovide the final Output Beams 12.

Another embodiment of a Drift/Deviation Correction Element 32 isillustrated in FIG. 6E wherein the characteristics of both an AngularCorrection NSE 28A and a Displacement Correction NSE 28B are combined ina single Angular/Displacement Correction NSE 28D, which may becomprised, for example, of a NSHOE. In this instance, the CorrectionAngle φ is a function of both the radial displacement of an impingingLaser Beam 12 from the HOE Axis 20 and the angle of incidence α of aLaser Beam 12 on the Angular/Displacement Correction NSE 28D, so thatthe single Angular/Displacement Correction NSE 28D performs the functionof both an Angular Correction NSE 28A and a Displacement Correction NSE28B.

In either embodiment, the output of the Drift/Deviation CorrectionElement 32 is passed through a Collimating NSE 28C to form a collimatedLaser Beam 12, and then through a Shaper Element 28S. It will beunderstood, in this regard, that Collimating NSE 28C and Shaper Element28S may be arranged in any order, and that these elements may becomprised of, for example, NSHOEs, HOEs, aspheric optical elements, orany other elements that will perform the required functions.

The results of the embodiment illustrated in FIG. 6E are illustrated inFIG. 6F for a possible distribution of Corrected Beams 12C about anOptimum Centerline 14 in comparison with Drift Uncorrected Beams 12DUand Angular Uncorrected Beams 12AU.

C. Compensator and Remapper NSEs

Having described the general method and apparatus of the presentinvention for correcting or compensating for the angular deviation andradial drift of laser beams, the following will next describe certainpresently preferred embodiments of the general principles and apparatusdescribed above.

Referring to FIGS. 7A, 7B and 7C, therein are illustrated embodiments ofexemplary Systems 34A, 34B and 34C, hereafter referred to generally as aSystem or Systems 34, that each include a Compensator/Remapper 36 of thepresent invention. As will be described, a Compensator/Remapper 36accepts an input beam over a range of input angles and lateraldisplacements and “remaps” the input profile of the input beam toprovide an output beam having an output profile that is optimum for afollowing element which shapes the input beam from Compensator/Remapper36 into a final output beam.

As illustrated in FIGS. 7A, 7B and 7C, a System 32 includes a Laser 38generating a laser beam, identified generally as Beam 40, that istransmitted along a Beam Path 42 to one or more Targets 44. It should benoted that in certain systems the Beam 38 may be divided into a group ofbeamlets that may be steerable individually or as a group and that forpurposes of the present descriptions will be collectively referred to asBeam 38. As shown, Beam Path 40 typically includes a number of OpticalElements 46, such as Lenses 46L and Mirrors 46M, that form, focus andshape Beam 38 along Beam Path 40.

The Optical Elements 46 of typical Laser System 32 may include, forexample, an Up Telescope Assembly 46LT, which is an assembly of multipleLenses 46L to initially shape and focus the Beam 38 emitted by Laser 36.Up Telescope Assembly 46LT may be followed by a Compensator/Remapper 34which, as described in further detail below, may be comprised of one ormore elements to remap an Input Beam 38I into the Compensator/Remapper34 into an Remapped Beam 38R having a Remapped Profile 38RP that isselected as optimum for a following Shaper 48 to remap into a finalShaped Beam 38S having a Shaped Profile 38SP. In a presently preferredembodiment in a System 32 for drilling microvias, for example, RemappedProfile 38RP may be a round Gaussian profile and Shaped Profile 38SPwill typically be a “flat top” profile, that is, a profile having agenerally even energy distribution across the diameter of the Beam 38. Afollowing Aperture 50 then further shapes the Beam 38S and, inparticular, shapes the cross sectional image of the Beam 38S.

Lastly, and as also shown, Beam Path 38 further includes fixed Mirrors42M and galvanometer controlled movable Mirrors 42M for redirecting andsteering Beam 30 or Beamlets 30B, and will typically include a finalLens 42L such as a F-Theta lens for final shaping and focus of the Beam30 or Beamlets 30B.

D. Compensator/Remapper 34

As described, and according to the present invention, Beam Path 40includes a Compensator/Remapper 34 which accepts an Input Beam 38Ihaving an Input Profile 38IP and “remaps” the profile of Input Beam 38Ito provide an Remapped Beam 38R having an Remapped Profile 38RP that isoptimum for a following Shaper 46 to remap into a final profile. In apresently preferred embodiment of the invention, a Compensator/Remapper34 includes a Compensator 34C element that accepts Input Beam 38I, whichwill typically have a beam or beam components having a range of inputangles and lateral displacements, and generates an Aligned Beam 38Aoutput having beam components that are essentially evenly distributedand parallel and that has, for example, a non-round profile so as toevenly illuminate a following Remapper 34R element. Remapper 34R thenremaps the output Aligned Beam 30A into the Remapped Beam 38R having anoptimum Remapped Profile 38RP, such as a round Gaussian profile, thatmay then be remapped by Shaper 46 into a Shaped Beam 38S having, forexample, a flat top profile.

E. Compensator 34C

In a presently preferred embodiment of a Compensator/Remapper 34, theCompensator 34C element is a computer generated hologram element, or“CGH”, that can be illuminated by an Input Beam 38I at different inputangles and with different lateral displacements, and will form thatInput Beam 30I into an evenly distributed, parallel Aligned Beam 38Awith which to illuminate Remapper 34R. In a present embodiment, forexample, Input Beam 38I to Compensator 34C may have essentially anyprofile and Aligned Profile 38AP may be, for example, a non-roundprofile.

In a presently preferred embodiment of the invention, Compensator 34C isimplemented as a hologrammic lens that is encoded over its entiresurface. The encoded surface of Compensator 34C or any part thereofthereby includes all of the information necessary to remap Input Beam38I into an Aligned Beam 38A and Compensator 34C will do so regardlessof where on its surface Compensator 34C is illuminated by the Input Beam38I. It should be noted, however, that a Compensator 34C may also beimplemented in other forms, as will be discussed in the following.

Considering the implementation and operation of a Compensator 34C infurther detail, discussed and illustrated above with reference to FIGS.6A-6F, either or both of radial displacement due to thermal drift andangular deviation due to pointing instability may be corrected by meansof a Compensator 34C that embodies and implements a Non-SymmetricElement (NSE) 28. As described, an NSE 28 may be, for example, aNon-Symmetric Hologram Optical Element (NSHOE), that is, a type of CGHelement, or an equivalent optical element such as a non-symmetric lensor a non-symmetric refraction element or a non-symmetric diffractionelement. As discussed, an NSE 28 differs from a SSHOE 18 or equivalentsymmetric element in that the path of the Beam Axis 10 of a Laser Beam12 traversing the NSE 28 is refracted, or turned, through a CorrectionAngle φ during the passage of the Laser Beam 12 through the NSE 28. Forexample, and as discussed above, in one embodiment of an NSE 28, theangle φ increases with increasing radial displacement Δ of the incidentBeam Axis 10 from the Centerline Axis 28C of the NSE 28. In anotherembodiment of a NSE 28, the Correction Angle φ increases with andecreasing angle of incidence α of the Beam Axis 10 of the incidentLaser Beam 12 with respect to the plane surface of the NSE 28.

Referring now to FIGS. 8A, 8B, 8C and 8D, therein are illustratedpresently preferred alternate embodiments of a Compensator 34C elementor elements for performing lateral drift and angular error correctionand compensation. As will be understood by those of ordinary skills inthe arts, a Compensator 34C element or elements may be implemented usingthe using the principles, structures and elements described herein abovewith respect to various forms of single and multiple NSEs 28. ACompensator 34C element or elements may be embodied as, for example,multi-function diffractive optical elements (MFDOEs), integratedmulti-function diffractive optical elements (IMFDOEs), multi-functionholographic optical elements (MFCGH) or multi-function fresnel prisms(MFFZPs) or other CGHs or optical assemblies capable of the desiredfunctions.

For example, the Compensator 34C illustrated in FIG. 8A is comprised ofa Substrate 52 bearing a Field Lens 54 on Input Side 501 and a DOEShaper 56 element on Output Side 50O wherein Field Lens 52 and DOEShaper 56 are comprised of holographic elements and wherein Field Lens52 also defines an Aperture 58. Field Lens 52 and DOE Shaper 54 aretypically CGH elements that are designed, as discussed above, to performthe lateral drift and angular error correction and compensationfunctions while Aperture 58 shapes the beam passing through theCompensator 34C and masks out portions of the Input Beam 30I that areoutside the ranges of Field Lens 52 and DOE Shaper 54.

FIG. 8B, in turn, illustrates a Compensator 34C that includes anAperture 58 but wherein DOE Shaper 54 is implemented as a CGH element onthe output face of a refractive lens element forming Field Lens 52. Asshown, this embodiment does not require a separate Substrate 50 as therefractive lens forming Field Lens 52 performs this function.

FIG. 8C illustrates an embodiment of a Compensator 34C employing aSubstrate 50 and wherein Field Lens 52 and Shaper 54 are integrated intoa single compound, or complex, holographic DOE lens element mounted onInput Side 52I of Substrate 54. This embodiment also includes anAperture 58, which is formed on the Output Side 54O of Substrate 54.

Finally, FIG. 8D illustrates an embodiment of a Compensator 34C whereinField Lens 52 and Shaper 54 are again integrated into a single compound,or complex, holographic DOE lens element mounted on Input Side 50I ofSubstrate 50. In this instance, however, Aperture 58 is formed by a DOEdeflection aperture surrounding the Field Lens 52/Shaper 54 element onInput Side 50I. As will be understood by those of skill in the arts, adeflection aperture is functionally an aperture, but operates to deflectaway those portions of Input Beam 30I that are outside the range of theField Lens 58/Shaper 60 element.

F. Remapper 34R

Referring now to FIG. 8F, therein is illustrated an embodiment of aRemapper 30R as may be used in a Compensator/Shaper 34 in conjunctionwith a Compensator 34C.

As described above, Compensator 34C is illuminated by an Input Beam 38Iwherein the components of Input Beam 38I may have different input anglesand different lateral displacements, and will form that Input Beam 38Iinto an evenly distributed, parallel Aligned Beam 38A with which toilluminate Remapper 34R. Aligned Beam 38A may, for example, have anon-round Gaussian profile and Remapper 34R remaps Aligned Beam 38A intoan Remapped Beam 38R having an optimum profile, designated as Profile38RP, which may be, for example, a round Gaussian profile. Remapped Beam38R is then remapped by Shaper 46 into a Shaped Beam 38S having a ShapedProfile 38SP, such as a flat top profile.

In a presently preferred embodiment, Remapper 34R is a CGH implementedas either a radial symmetric diffractive optical element (RSDOE) or anon-symmetric diffractive optical element (NSDOE) that accepts theevenly distributed, parallel Aligned Beam 38A from Compensator 34C andcollimates, converges and remaps the profile of Aligned Beam 38A, whichmay be a non-round Gaussian profile, to form an Remapped Beam 38R havingthe desired profile for Shaper 46, such as a round Gaussian profile.

While it will be understood from the above discussions that aCompensator/Remapper 34 of the present invention may be constructed froma number of elements arranged in a number of ways, certain of which havebeen described above, the presently preferred configuration of aCompensator/Remapper 34 is a two element design having a DOE elementfollowing a CGH element. In this two element configuration, theseparation between the optics of the two elements is on the order of 50mm to 1500 mm with an optimum distance in the range of 50 mm and theoptimum clear aperture of the Compensator/Remapper 34 is in the order of04. Mm to 25 mm.

Lastly, the above described optical elements of the present inventionare commercially available and may be obtained from or manufactured by,for example, MEMS Optical of Huntsville, Ala., Heptagon of Finland, SussMicro Optics of Neuchatel, Switzerland, or Digital Optics Corporation ofCharlotte, N.C.

G. Beamshaping by Radially Non-symmetric Diffractive and HolographicBeamforming Optical Elements to Correct Lateral Shift Distortion

It has been described herein above that beamshaping optics are commonlyused, for example, to reshape an Input Beam 12I having an optimumGaussian Profile 12GP into an Output Beam 12O having a Flat-Top Profile12FP. It has also been described, however, that the for various reasonsthe laser beam inputs to beamshaping optics may be subject to lateralshifts, that is, radial shifts relative to the optical centerline of thebeamshaping optics. As discussed, such lateral shifts in an input beamcan result in the generation of undesired “hotspots” or “deficiencies”in the energy profile of the Output Beam 12O.

As also discussed herein above, non-symmetric optical elements may beemployed to correct radial displacement of a laser beam due to thermaldrift and angular deviation of a laser beam due to pointing instability.Compensator and remapping elements may also be employed to “remap” theenergy profile of an input beam to provide an output beam having anoutput profile that is optimum for a following element, such asbeamshaping elements. While these methods may be employed to address theproblems arising from lateral shifts of laser beams into beamshapingoptics by redirecting or reshaping the laser beam as necessary, it willbe appreciated that these methods may not be applicable or desirable inall instances. For example, the use of additional optical elements mayincrease the cost or complexity or both of a system to unacceptable oruneconomic levels, or may reduce the energy transfer efficiency of thesystem unacceptably.

Also, such non-symmetric optical elements, including compensator andremapping elements, are typically comprised of holographic ordiffractive optical elements and, as such, typically have fixedcharacteristics. The lateral shifts of a laser beam, however, are notfixed but may vary over a relative wide range of directions and amounts,so that holographic and diffractive optical elements may not be able toadequately address the full range of possible lateral shifts of a laserbeam in a given system.

According to this aspect of the present invention, therefore, theproblems arising from lateral shifts of the input beams to beamformingoptical elements should preferably, and in many instances, be resolvedwithout the need for additional optical elements. In addition, thesolution to these problems should preferably be provided by fixedoptical elements, such as holographic or diffractive optical elementshaving fixed characteristics, and fixed optical elements are lessexpensive and less complex than variable elements. The solution should,however, allow ready adjustment or adaptation of the fixed opticalelements to the actual lateral shifts of the input laser beam whereinthe actual lateral shifts may occur over relatively wide ranges in bothdirection and amount.

FIGS. 9A and 9B illustrate a Non-Symmetric Beamforming Optical Element62 having a Beamforming Transform Function 62T for reshaping an InputBeam 12I having a Gaussian Profile 12GP into an Output Beam 12O having aFlat-Top Profile 12FP when Beam Axis 10 of Input Beam 12I has a LateralShift 64 relative to the optical axis of Beamshaping Optical Element 62.

As illustrated diagrammatically in FIGS. 9A and 9B, the energy profiletransform function implemented in Non-Symmetric Beamforming OpticalElement 62 as Beamforming Transform Function 62T is designed totransform an input Gaussian Profile 12GP into a Non-Symmetric Profile12NP. As will be described below, Non-Symmetric Profile 12NP and thecorresponding Beamforming Transform Function 62T are designed tocompensate for the expected range of beamforming distortions introducedby lateral shifts of the input beam. In this regard, and in regard tothe following descriptions, it must be emphasized that BeamformingTransform Function 62T is determined by and is a function of theGaussian Profile 12GP of Input Beam 12I, the expected range of lateraloffsets of Input Beam 12I, and the Non-Symmetric Profile 12NP necessaryto result in the desired Flat-Top Profile 12FP for Output Beam 12O.

The transformation function performed by Beamforming Transform Function62T may be illustrated by reference to FIGS. 9A and 9B and byconsidering the Non-Symmetric Profile 12N resulting from illumination ofBeamforming Transform Function 62T by an Input Beam 12I having aGaussian Profile 12GP and Beam Axis 10 centered on the OpticalCenterline 62C of Non-Symmetric Beamforming Optical Element 62. ABeamforming Transform Function 62T generating an Output Beam 12O havinga Non-Symmetric Profile 12NP from the Input Beam 12I is designed suchthat the Non-Symmetric Profile 12NP contains features compensating forthe distortions caused by lateral offsets of the Input Beam 12I withrespect to the Non-Symmetric Beamforming Optical Element 62.

In an exemplary case as illustrated in FIGS. 9A and 9B, theNon-Symmetric Profile 12NP is effectively comprised of a Flat-TopProfile 12FP with a superimposed Compensation Profile 12CP wherein thespecific form of Compensation Profile 12CP will depend upon the specificdistortion introduced to the profile of Output Beam 12O by drift ofInput Beam 12I. In a typical example, and for example, a CompensationProfile 12CP may include either or both of a superimposed Non-SymmetricHotspot Profile 62HP and a superimposed Non-Symmetric Deficiency Profile62DP, depending upon the anticipated distortions that may be introducedby a lateral shift of the input beam.

Considering each of the components of the exemplary Compensating Profile12CP individually, a Non-Symmetric Deficiency Profile 62DP is designedto compensate for or to cancel out, to at least a significant degree, aHotspot 64H generated in the energy profile of the Output Beam 12Obecause an offset of the Input Beam 12I. As illustrated, a Non-SymmetricDeficiency Profile 12DP is typically offset from the Optical Centerline62C of Beamforming Optical Element 62 along a Transform Radius 62R andtowards the outer circumferential edge of the Flat-Top Profile 12FPcomponent of Non-Symmetric Flat-Top Profile 12NP so as to generally besuperimposed on a potential Hotspot 64H. A Non-Symmetric DeficiencyProfile 12DP typically does not extend around the complete circumferenceof Non-Symmetric Flat-Top Profile 12NP, but only a portion thereof thatis expected to contain a Hotspot 64H. It should also be noted thatTransform Radius 62R typically extends in the radial, or lateral,direction in which the Beam Axis 10 of Input Beam 12I is shifted withrespect to Optical Centerline 62C of Non-Symmetric Beamforming OpticalElement 62 as this is the direction in which a Hotspot 64H willtypically occur.

A Non-Symmetric Hotspot Profile 62HP, in turn, is intended to compensatefor or cancel out, to at least a significant degree, a Deficiency 64Dgenerated in the energy profile of the Output Beam 12O due to an offsetof the Input Beam 12I. A Non-Symmetric Hotspot Profile 62HP is typicallyoffset from the Optical Centerline 62C of Non-Symmetric BeamformingOptical Element 62 along a Transform Radius 62R and towards the outercircumferential edge of the Flat-Top Profile 12FP component ofNon-Symmetric Flat-Top Profile 12NP. A Non-Symmetric Hotspot Profile62HP again typically does not extend around the complete circumferenceof Non-Symmetric Flat-Top Profile 12NP, but only a portion thereof thatis expect to contain a Deficiency 64D. It should be noted, however, thatin this case the Transform Radius 62R typically extends in the radial,or lateral, direction opposite to that in which the Beam Axis 10 ofInput Beam 12I is shifted with respect to Optical Centerline 62C ofNon-Symmetric Beamforming Optical Element 62, that is, in the generallyopposite direction to a Non-Symmetric Deficiency Profile 62DP, as thisis the direction in which a Deficiency 64D will typically occur.

Briefly considering Beamforming Transform Function 62T, as describedabove a Beamforming Transform Function 62T is defined according to theenergy profile of the Input Beam 12I, the energy profile of the OutputBeam 12O and the Compensating Profile 12CP required to compensate for orto correct the distortions expected to arise from the anticipatedlateral shifts of Input Beam 12I. In the present example, therefore, andin correspondence with the Non-Symmetric Profile 12NP, the BeamformingTransform Function 62T would be comprised of a Flat-Top TransformFunction 62TF with a superimposed Compensation Transform Function 62CTcomprised, in turn, of either or both of a Hotspot Transform Function62TH and a Deficiency Transform Function 62TD.

The operation of a Non-Symmetric Beamforming Optical Element 62 may beillustrated by consideration of the energy profiles of the Output Beams12O generated when the Non-Symmetric Beamforming Element 62 isilluminated by Input Beams 12I having Beam Axes 10 that are and are notoffset with respect to the Optical Centerline 62C of Non-SymmetricBeamforming Optical Element 62. When Input Beam 12I is not offset withrespect to the Non-Symmetric Beamforming Optical Element 62, theresulting Output Beam 12O will accordingly have a Non-Symmetric Profile12NP comprised of a Flat-Top Profile 12FP with either or both of asuperimposed Non-Symmetric Hotspot Profile 12HP and a Non-SymmetricDeficiency Profile 12HD, depending upon the specific BeamformingTransform Function 62T. It must be noted, however, that if the InputBeam 12I is not laterally shifted there may be no distortion of theenergy profile, so that the Beamforming Transform Function 62T mayintroduce distortions in the Output Beam 12O energy profile inattempting to correct distortions that are not present. Thisconsideration will be discussed further in the following, however.

When Beamforming Optical Element 62 is illuminated by an Input Beam 12Ishifted from Optical Centerline 62C of Beamforming Optical Element 62,however, the resulting Output Beam 12O will have a Flat-Top Profile 12F.This result occurs because the Compensation Transform Function 62CTcomponent of Beamforming Transform Function 62T introduces distortions,such as Hotspots 64H and Deficiencies 64D, in the energy profile ofOutput Beam 12O to compensate for or cancel distortions arising from thelateral shift of the Input Beam 12I.

Next considering further aspects of the present invention, it has beendescribed herein above that a Lateral Shift 64 of the Beam Axis 10 of anInput Beam 12I may vary widely in direction and magnitude relative tothe unshifted path of the beam through the system, that is, relative toOptical Centerline 64C of the Non-Symmetric Beamforming Optical Element62. Beamforming Transform Function 62T is non-symmetric, however, sothat the effect of Beamforming Transform Function 62T on the energywaveform of the input and output beams will thereby dependent upon boththe radial direction as well as the magnitude of a Lateral Shift 64relative to Beamforming Transform Function 62T.

Stated another way, it has been described that the circumferentiallocations of hotspots and deficiencies in an output beam energy profileare dependent upon the radial direction of the lateral shift of theinput beam. As such, the locations of the hotspots and deficiencies inthe output beam energy profile will appear to rotate about the axis ofthe output beam proportional to the radial direction of the lateralshift. Beamforming Transform Function 62T is non-symmetric, so that ifthe rotational position of the Beamforming Transform Function 62T isfixed variations in the radial direction of the lateral shifts willappear as rotational shifts or offsets of the resulting hotspots ordeficiencies with respect to the rotational orientation of theBeamforming Transform Function 62T. A rotational mismatch between theBeamforming Transform Function 62T and the lateral shift may therebyresult in non-correction of the hotspots and deficiencies by theBeamforming Transform Function 62T, and even the introduction of furtherhotspots or deficiencies introduced by the Beamforming TransformFunction 62T.

In addition, and a discussed, when Input Beam 12I is aligned with theaxis of Non-Symmetric Beamforming Optical Element 62, that is, whenthere is no lateral shift of the input beam, the Beamforming TransformFunction 62T may in fact introduce the distortions that it is intendedto eliminate by introducing hotspots or deficiencies to correctdeficiencies or hotspots that are not actually present due to the lackof a lateral shift.

Non-Symmetric Beamforming Optical Element 62 must therefore be designedto accommodate variations in the direction and magnitude of lateralshifts of the input beam and to avoid alignments of the input beam withthe Non-Symmetric Beamforming Optical Element 62 that would introducerather than correct distortions in the output beam.

In addition, a Non-Symmetric Beamforming Optical Element 62 ispreferably constructed of fixed optical elements, such as diffractive orholographic beam diffusers or shaping optics, to reduce complexity andcosts. As a consequence, however, a given Non-Symmetric BeamformingOptical Element 62 may provide a compensating effect over only arelatively small range of lateral shift magnitudes and angles.

These problems may be addressed by the design of a Non-SymmetricBeamforming Optical Element 62, however. For example, and firstconsidering variations in the magnitudes of the lateral shifts,including the condition where there is no lateral shift, in a presentlypreferred embodiment the Non-Symmetric Beamforming Optical Element 62 issupported by an Offset Mount 68. As illustrated in FIG. 9C, the OffsetMount 68 supports the Non-Symmetric Beamforming Optical Element 62 sothat Optical Centerline 64C of the Non-Symmetric Beamforming OpticalElement 62, that is, of the Beamforming Transform Function 62T, isparallel to the nominal Beam Axis 10, but offset with respect to thenominal Beam Axis by an Offset 70. Offset 70, in turn, is selected to beapproximately equal to or slightly greater than the expected maximumLateral Shift 64 of Input Beam 12I, so that Beam Axis 10 will notcoincide with Optical Centerline 64C even under a maximum Lateral Shift64 towards Optical Centerline 64C.

In addition, the Beamforming Transform Function 62T is preferablydesigned with a “width” or “diameter” adequate to accommodate theexpected directions and maximum expected magnitudes of Lateral Shift 64.Stated another way, the Beamforming Transform Function 62T is designedwith a radius equal to or slightly greater than the maximum expectedLateral Shift 64 to thereby provide the width necessary to accommodatethe maximum expected Lateral Shift 64.

Given the offset of Beamforming Transform Function 62T by Offset Mount68, therefore, Input Beam 12I will always pass through the BeamformingTransform Function 62T between Optical Centerline 64C and the outerdiameter of the Beamforming Transform Function 62T, thereby assuringthat the Input Beam 12I will pass through the Beamforming TransformFunction 62T even under the maximum magnitude Lateral Shift 64 andregardless of the direction of the Lateral Shift 64. In addition, andbecause the Offset 70 is greater than the maximum Lateral Shift 64 ofthe Input Beam 12I, the Input Beam 12I will never coincide with OpticalCenterline 64C, thereby avoiding the introduction of unwanteddistortions by the Beamforming Transform Function 62T due to the lack ofdistortions to correct.

Lastly in this regard, it should be noted that the distorting effects ofa Lateral Shift 64 of the Input Beam 12I will typically increase withthe magnitude of the Lateral Shift 64. In compensation, however, theeffects of the component elements of the Compensating Transform Function62CT, such as either or both of a Hotspot Transform Function 62TH and aDeficiency Transform Function 62TD, may be designed to likewise increasewith increasing Lateral Offsets 64 so that the correcting effects of theCompensating Transform Function 62CT track the magnitude of the lateraloffset.

As a consequence of the above described aspects of the presentinvention, the effects of variations in the magnitude of the offset ofthe input beam relative to the axis of the Beamforming TransformFunction 62T will thereby tend to be self compensating. That is, adecrease or increase in the magnitude of the offset will move the inputbeam radially inward or outward along either or both of the HotspotTransform Function 62TH and the Deficiency Transform Function 62TD,thereby resulting in a decreased or increased offset compensationeffect. As such, and so long as the Beamforming Transform Function 62Tcan accommodate the greatest expected offset magnitude, a satisfactoryadaptation to the magnitude of the offset can often be achieved withoutfurther complexity. It should be noted, however, that it is generallypreferable that the Beamforming Transform Function 62T not be designedto accommodate an excessively large offset as this may reduce the “fit”between the transform function and the offset at lower offset ranges.

Next considering the effects of variations in the radial directions ofthe lateral shifts of the input beams, it has been described hereinabove that such variations in the radial direction of lateral shiftsappear as apparent rotational shifts or offsets of the distortionsappearing in an output energy profile with respect to the rotationalorientation of the Beamforming Transform Function 62T. For example, thecircumferential “gradients” of the Non-Symmetric Hotspot Profile 12HPand Non-Symmetric Deficiency Profile 12HD components of thetransformation function may be relatively “steep”, so that a relativelysmall rotational offset may have major effects. This is a particularconcern when there are, for example, both Hotspot Transform Functions62HT and Deficiency Transform Functions 62DT components or when thetransform functions are otherwise rotationally non-symmetric.

According to the present invention, the effects of such apparentrotational shifts or offsets between the distortions appearing in theoutput profile due to a lateral shift of the input beam and therotational orientation of the Beamforming Transform Function 62T arepreferably accommodated by rotation of the Beamforming TransformFunction 62T about Optical Centerline 64C. According to the presentinvention, therefore, and as illustrated in FIG. 9D, the Non-SymmetricBeamforming Optical Element 62 is supported in the Offset Mount 68 byRotating Bearings 72 that allow Non-Symmetric Beamforming OpticalElement 62 to be rotated about Optical Centerline 64C of the BeamformingTransform Function 62T to achieve the optimum rotational relationshipbetween a laterally shifted Input Beam 12I and Beamforming TransformFunction 62T.

In this regard, it must also be noted that the non-symmetry of theBeamforming Transform Function 62T together with appropriate shaping ofthe components of the Beamforming Transform Function 62T will typicallyallow the Beamforming Transform Function 62T to be adjusted tocompensate for various magnitudes of Lateral Shifts 64 as well as tovariations in the radial direction of the Lateral Shifts 64.

According to the present invention, therefore, the effect of BeamformingTransform Function 62T on the energy waveforms of an Input Beam 12I andan Output Beam 12O will depend upon both the magnitude and angulardirection of a lateral shift of the input beam relative to Non-SymmetricBeamforming Optical Element 62. Further according to the presentinvention, the effects of variable lateral and rotational offsets of anInput Beam 12O resulting in distortion of the energy profile of theoutput beam may be compensated to result in an output beam having adesired energy profile by a beamshaping element having an energy profiletransformation function that is offset by a fixed amount with respect tothe input beam and that is longitudinally rotational with respect to theinput beam. Further according to the present invention, the energyprofile transformation function may include either or both of a hotspotprofile transformation component and a deficiency profile transformationcomponent and an optimum lateral and rotational relationship between anInput Beam 12I and the Beamforming Transform Function 62T to achieve adesired output beam energy profile may be adjustably achieved byadjusting the rotational orientation of the Beamforming TransformFunction 62T with respect to the Input Beam 21I.

Example of Beamforming Transform Function 62T FIG. 9E

In a further aspect of the present invention and as also illustrated inFIG. 9D, the alignment and realignment of a Beamforming TransformFunction 62T with respect to an Input Beam 12I subject to variablelateral drift in order to obtain a desired Output Beam 12O energyprofile may be readily automated. In this implementation, a partiallycoated Mirror 76 is mounted in the Output Beam 12O path to reflect animage of the Beam 12 to an Optical Sensor 78, such as a charge coupleddevice or a sensor made of photo-sensitive resistive materials, that canthereby monitor the energy distribution profile of the Output Beam 12Oby its image in the appropriate portion of the spectrum. For example,Optical Sensor 78 may be a two dimensional position sensitive detectoras manufactured and distributed by Hamamatsu Corp. The imagerepresenting the energy distribution profile of Output Beam 12O is thenpassed to Processor/Controller 80, which determines whether the OutputBeam 12O energy distribution profile is in accordance with the desiredprofile. If Processor/Controller 80 determines that the Output Beam 12Oenergy distribution profile does not match the desired profile withinacceptable tolerances, Processor/Controller 80 will drive RotatingBearings 72 through a suitable Drive Mechanism 82 to rotate theNon-Symmetric Beamforming Optical Element 62 until the rotationalorientation between Input Beam 12I and Beamforming Transform Function62T yields the desired Output Beam 12O energy profile.

Finally, the present invention as described above is further illustratedby reference to FIGS. 10A and 10B, which are phase surface illustrationsof two exemplary non-symmetric beamforming optical elements according tothe present invention, and FIGS. 10C and 10D, which are correspondingcross-section profile views.

The present invention is still further illustrated by reference to FIGS.11A through 11E, which illustrate cross sectional energy profiles oflaser beams according to the present invention. For example, FIG. 11Aillustrates a beam having a hot spot, at the left side, but which has agenerally acceptable energy profile. FIG. 11B illustrates a beamdrifting to the right and wherein the beam profile improves, due to anoptical element of the present invention, the further the beam drifts tothe right. FIG. 11C illustrates a beam that has drifted to the right bya distance of 100 microns, which is optimum for the illustratednon-symmetric beamforming optical element. FIG. 11D illustrates the casewherein the beam has continued to drift to the right, by 150 microns,and wherein the right side of the profile as started to “rise” as aresult. Lastly, FIG. 11E illustrates a case wherein the beam has drifted200 microns to the right, which results in a situation that is themirror of that illustrated in FIG. 11A. These examples thereforeillustrate that a non-symmetric beamforming optical element of thepresent invention as illustrated can accommodate a beam drift of, forexample, up to 200 microns , while still providing an acceptable beamprofile.

Since certain changes may be made in the above described inventionwithout departing from the spirit and scope of the invention hereininvolved, it is intended that all of the subject matter of the abovedescription or shown in the accompanying drawings shall be interpretedmerely as examples illustrating the inventive concept herein and shallnot be construed as limiting the invention.

1. A radially non-symmetric beamforming element for transforming aninput energy profile of an input laser beam having a beam axis subjectto lateral shift that is variable in radial direction and magnitude intoan output laser beam having a desired output energy profile, comprising:an optical element including a profile transformation function,including a first profile transformation function for transforming theinput energy profile into the desired output energy profile, and aprofile correction transformation function superimposed on the firstprofile transformation function for modifying the first profiletransformation function to correct distortions in the output energyprofile introduced be a lateral shift of the input laser beam.
 2. Theradially non-symmetric beamforming element of claim 1, wherein theprofile correction transformation function includes: at least one of adeficiency profile transformation function superimposed on the firstprofile transformation function for superimposing a compensatingdeficiency energy profile on the desired output energy profile in alocation corresponding to a hotspot resulting from a lateral shift ofthe input laser beam, and a hotspot profile transformation functionsuperimposed on the first profile transformation function forsuperimposing a compensating hotspot energy profile on the desiredoutput energy profile in a location corresponding to a deficiencyresulting from a lateral shift of the input laser beam.
 3. The radiallynon-symmetric beamforming element of claim 1, wherein: an optical axisof the beamforming element is aligned parallel to the beam axis of theinput laser beam and is offset from an unshifted beam axis of the inputlaser beam by a distance proportionate to a maximum expected lateralshift of the beam axis of the input laser beam, so that the input laserbeam passes through the beamforming element parallel to and offset fromthe optical axis of the optical element.
 4. The radially non-symmetricbeamforming element of claim 3, wherein: the beamforming element issupported in a rotating mount allowing rotation of the profiletransformation function about the optical axis of the optical element toallow adjustment of the profile transformation function to a currentlateral shift of the input laser beam.
 5. A method for transforming aninput energy profile of an input laser beam having a beam axis subjectto lateral shift that is variable in radial direction and magnitude intoan output laser beam having a desired output energy profile, comprisingthe steps of: performing a profile transformation function on the inputlaser beam, including performing a first profile transformation functionto transform the input energy profile into the desired output energyprofile, and performing a profile correction transformation functionsuperimposed on the first profile transformation function to modify thefirst profile transformation function to correct distortions in theoutput energy profile introduced be a lateral shift of the input laserbeam.
 6. The method of claim 5 for transforming an input energy profileof an input laser beam subject to lateral shift that is variable inradial direction and magnitude into an output laser beam having adesired output energy profile, further comprising the steps of:performing at least one of a deficiency profile transformation functionsuperimposed on the first profile transformation function to superimposea compensating deficiency energy profile on the desired output energyprofile in a location corresponding to a hotspot resulting from alateral shift of the input laser beam, and a hotspot profiletransformation function superimposed on the first profile transformationfunction to superimpose a compensating hotspot energy profile on thedesired output energy profile in a location corresponding to adeficiency resulting from a lateral shift of the input laser beam. 7.The method of claim 5 for transforming an input energy profile of aninput laser beam subject to lateral shift that is variable in radialdirection and magnitude into an output laser beam having a desiredoutput energy profile, wherein: the profile transformation function andprofile correction transformation function are incorporated into abeamforming element, and an optical axis of the beamforming element isaligned parallel to the beam axis of the input laser beam and is offsetfrom an unshifted beam axis of the input laser beam by a distanceproportionate to a maximum expected lateral shift of the beam axis ofthe input laser beam, so that the input laser beam passes through thebeamforming element parallel to and offset from the optical axis of theoptical element.
 8. The method of claim 7 for transforming an inputenergy profile of an input laser beam subject to lateral shift that isvariable in radial direction and magnitude into an output laser beamhaving a desired output energy profile, wherein: the beamforming elementis supported in a rotating mount allowing rotation of the profiletransformation function about the optical axis of the optical element,and further including the step of adjusting of the profiletransformation function to a current lateral shift of the input laserbeam by rotation of the beamforming element